Flat foldable carton having a preformed, anchored in place, and folded bottom, with self-locking top

ABSTRACT

A carton is provided which may be prepared from an integral blank and which when properly glued together, may be stored in flat folded condition. The folded carton may be quickly erected to form a carton in the form of a polygonal prism having a closed bottom and another end which is readily closable by interlocking a plurality of flaps.

United States Patent .1151 3,700,161 Bundy [451 0a; 24, 1972 [54] FLAT FOLDABLE CARTON HAVING A 2,741,416 4/1956 Hileman ..229/41 C PREFORMED, ANCHORED IN PLACE, 3,174,675 3/1965 Rosenburg, Jr. ..229/41 C AND FOLDED BOTTOM, WITH SELF- 3,101,167 8/1963 Styler ..229/41 C LOCKING TOP 2,044,103 6/1936 Rossi ..229/37 Inventor: z g B y, Battle Creek, FOREIGN PATENTS 0R APPLICATIONS 1 693,421 9 1964 C d ..229 41 C [73] Assrgnee: Michigan Carton Co., Battle Creek, I an a Mlch' Primary Examiner-Davis T. Moorhead 221 Filed: July 15, 1970 y-R y Plant Acarton is provided which may be prepared from an :ttSIIL ..zz9l4llglszdzglg9 integral l k d hi h wh n properly glued [58] Fieid C 39 together, may be stored in flat folded condition. The

""""""" folded carton may be quickly erected to form a. carton in the .form of apolygonalprism having a closed bot- [56] 1 References Cited tom and another end which "is readily closable by in- UNITED STATES PATENTS lerlocking a p a y of p 3,526,352 9/1970 Swett ..229/41 C X' 8 Claims, 14 Drawing Figures 56 :4 J7 4/ M f/va 1' 42: 4i 45 4i4/ vlilly fglfi'l 35 5 Y I? i 1 {'2 Z Q7 Q 29 30 3/ /2 a L C /7 W 47 Z 7! V 74 9'? =E. Z7\\\ 4 M i5 =1} 2% PATENTED 2 I972 3.700.181

sum 1 OF 3 if 56 6 37 A 6% INVENTOR PATRICK L. BUNDY v GEQCLW ATTORNEY PATENTEDUCT 2 I912 3.700.161

' sum 2 BF 3 g Ma 4% {/35 INVENTOR F166 I PATRICK L..BUNDY v BY GEE] ATTORNEY PATENTED ET 24 I972 3.700.161

sum 3 0r 3 T1612 FIG. 9

I INVENTOR PATRICKIL. BUNDY away:

ATTORNLY FLAT FOLDABLE CARTON HAVING A PREFORMED, ANCHORED IN PLACE, AND FOLDED BOTTOM, WITH SELF-LOCKING TOP BACKGROUND OF THE INVENTION The invention deals broadly with foldable boxes or cartons, and more particularlyrefers to such cartons which may be erected into polygonal and preferably hexagonal prism form having one closed end and another which is readily closed and locked.

Polygonal and particularly hexagonal cartons have been disclosed in the art, but because of their form, they are generally not able to be folded flat for storage. However, even where collapsible hexagonalcartons have been provided, the strength and rigidity particularly of the bottom end are not sufficient for containing such articles as parts of fried chicken. Such items are generally placed in bucket-type paper cartons which are not foldable, and therefore require a considerable amount of storage space.

SUMMARY OF THE INVENTION I Accordingly, it is an object of the present invention to provide a carton which can be glued and erected in the shape of a polygonal and preferably hexagonal prismatic form.

It is a particular object of the invention to provide a bottom for the carton which, although it may be folded flat for storage, it can be readily set up to provide a strong, full bottom which additionally aids in retaining the polygonal shape of the carton.

It is still further an object to provide a carton having such a bottom which will contain even small items without danger of less. 7

It is still further an object to provide a hexagonal carton having improved closing and locking means.

It is an additional object to provide a canon of the type described which can be formed of an integral blank suitably cut and scored.

Still further objects and advantages of the invention will appear as the description proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS closed carton according to the invention illustrating the top closure. I

FIG. 2 is a perspective view of the carton of FIG. 1 illustrating the bottom closure.

FIG. 3 is a plan view of an integral blank which may be utilized to form a carton-such as shown in FIGS. 1 and 2.

FIG. 4 is a plan view of a carton which has been glued together but which is folded flat in storage condition.

FIG. 5 is an end view taken at the line V-V of FIG. 4, looking in the direction of the arrows.

FIG. 6 is a top view of the carton of FIGS. l-S which has been glued, the bottom folded in place, and the top flaps open for filling the carton.

FIG. 7 is a top view of the carton of FIG. 6 in which the flaps are in partially closed condition.

- FIG. 8 is a top view showing the carton of FIGS. 6 and 7 with the top completely closed and the flaps interlocked.

FIG. 9 is a side elevational view showing the top not completely closed.

FIG. 10 is a fragmentary elevational view showing the top completely closed.

FIG. 11 is a cross-sectional view taken at line XI-XI of FIG. 10, looking in the direction of the arrows.

FIG. 12 is a bottom view of the carton of the invention.

FIG. 13 is a sectional view taken at the line XIII- XIII of FIG. 12, looking in the direction of the arrows; and

FIG. 14 is a sectional view taken at the line XIV- XIV of FIG. 13, looking in the direction of the arrows.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS Referring more particularly to FIGS. 1 and 2,.the carton 10 is shown in perspective having a top closure 33 and a bottom closure 34. FIG. 3 illustrates an integral blank 11 from which the carton may be constructed and in which the various panels may be more clearly distinguished. The carton comprises side panels 12,13,14, 15, 16 and 17, and a glue flap 18 and 18a for afiixing the edge of the panel 17 to the edge of the panel 12 by means of an adhesive 19 such as glue applied to the edge of the panel 12 and flap 20. The top closure is comprised of a plurality of top flaps 20, 21,

22, 23, 24 and 25 affixed to the ends of the side panels at hinge lines 26, 27, 28, 29, 30 and 31, respectively. The top flaps are connected together by triangular webs 36, 37, 38, 39, 40 and 41 at hinge lines 42, 43, 44, 45, 46, 47,48, 49, 50, 51, 52 and 32. Each of the top flaps 20-25 have one lateral edge (35, 43, 45, 47, 49 and 51) perpendicular to the respective fold lines 26-31 of the flaps. Additionally, each flap 20-25 has one lateral edge (42, 44, 46,-48, 50 and 52) oblique with respectto the fold lines 26-31 of the flaps. In similar manner, each of the triangular webs 36-41 has a lateral edge (43, 45, 47, 49, 51 and 32) perpendicular to the fold lines 26-31, and another lateral edge (42, 44, 46, 48, 50 and 52) oblique to the fold lines. This arrangement permits the flaps 20-25 to be positioned either co-planar with the lateral panels 12-17 to present an open end of the carton, or alternatively perpendicular to the panels and cooperating with the triangular webs to form the interlocking pattern shown in FIG. 1. Each of the flaps 20-25 are provided at their ends with semi-circular tabs 53, 54, 55, 56, 57 and 58.

The bottom closure, FIG. 3, comprises a hexagonal flap 65 having a tab 64 at its end, and a pair of supporting flap assemblies. One supporting flap assembly 66 comprises a supporting flap member 67 and a triangular glue flap member 68 connected thereto at a hinge line 69. An end supporting flap 70 is hingedly connected to the side panel 14. At the other side of the hexagonal flap 65 is another flap assembly comprising a supporting flap member 76 and a triangular glue flap member 77 connected thereto at a hinge line 78. The flap members 67 and 76 are provided with arcuate or rounded edges to prevent entanglement with other flaps or panels. An end supporting flap 79 is hingedly connected to the side panel 16. The end supporting flaps 70 and 79 are provided with recesses 85 and 86, respectively, to provide clearance of the hexagonal flap 65. Ventilation holes 60, 61 and 62 may be provided in the carton top if desired.

In gluing the carton together, the hexagonal flap 65 is first folded over against the side panels 14, 15 and 16. The flap assembly 75 and end supporting flap 79 are then folded over against the side panels 16 and 17 The triangular glue flap member 77 is then folded back against the flap 76 and glue placed on the exposed surface of the triangular glue flap 77. The side panel 17 is then folded over against the side panel 16. The triangular glue flap 77 is thereby adhesively affixed to a medial portion of the end supporting flap79 but leaving an overhang 79a, FIG. 14, of the flap 79 beyond the glue flap supporting member 77. The flap assembly 66 and end flap 70.are then folded over against the side panels 13 and 14. The triangular glue flap member 68 is then folded back against the flap 67 and glue applied. The panel 13 is then folded over against the panel 14, cansing the triangular glue flap member 68 to be adhesively affixed to a medial portion of the end flap 70 but leaving an overhang 70a, FIG. 14. Glue 19 is then applied to the edge of the side panel 12 and end panel 20 which are then caused to be affixed to the glue strip 18 and 18a, the carton then being of the form shown in FIGS. 4 and 5, and in which condition the carton may be stored and transported.

The carton is erected by compressing together the opposite side edges, thereby opening the carton, and then pushing the hexagonalflap 65 outwardly until it engages the glued together flaps 67 and 70, and 76 and 79, which flaps retain the hexagonal flap 65 in position. The tab 64 is at the same time bent until its flap surface engages the panel 12, thereby forming a substantially leakproof container, as shown in FIGS. 12, 13 and 14. In this condition the overhanging areas 70a and 79a reinforcethe bottom and prevent outward bending of the flap at the hinge lines 69 and 78 (FIGS. l2, l3 and 14).

After the desired contents have been placed in the carton, the carton is closed by first forming a star pattern such as shown in FIG. 7, and pinching toward the center, as shown in FIGS. 7 and 9. When the flaps reach the flattened position as shown in FIGS. 8, and 11, the flaps are interlocked and the top remains closed. The top may be opened by raising and disengaging the flaps.

The carton of the present invention has many advantages over prior art cartons. Because of the arrangement of the bottom flaps which are glued together and which sustain the hexagonal flap,'an exceedingly strong supporting bottom structure is formed. The closure structure is further strengthened by the presence of the supporting flap overhangs which prevent the flaps from bowing outward at the glue flap hinge lines. Moreover, the bottom flaps are so arranged that they may be folded for storage. Additionally, because of the unique pattem of the flaps and because of the way in which they fold, the entire carton may be readily folded flat for storage and transportation, and subsequently quickly erected. The unique arrangement of the top flaps provides a positive locking and attractively appearing top.

While but one embodiment of the invention has been illustrated and described herein, it is to be understood that minor modifications may be made to the carton, as well as the construction and arrangement of its bottom flaps within the spirit and scope of the invention, as herein set forth. It is also to be noted that while directional terms have been used, same are not to be construed as a limitation of the invention since such use has been availed of to better describe the invention in the position illustrated in the drawings.

Other modes of applying the principle of my invention may be employed instead of those explained, change being made as regards the structure herein disclosed, provided those defined by any of the following claims or their equivalents be employed.

I therefore particularly point out and distinctly claim as my invention:

' 1. A carton in the form of a hexagonal prism having six side panels, and a bottom closure for said carton, said bottom closure comprising:

a. a hexagonal bottom panel being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton, and

b. two supporting flap assemblies disposed one immediately on each side of the side panel to which said hexagonal bottom panel is connected and below said polygonal bottom flap, each of said assemblies comprising:

1. a first supporting flap hingedly connected to the end of one of said side panels,

2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto,

3. said second glue flap being adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion (a, 79a) extending beyond the hinge line between said supporting member-and said glue member and positioned over said second glue flap, thereby strengthening vertical support of said flap assembly, and

4. one of said side panels being free of flap attachments at its lower edge,

the arrangement being such that each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhanging portion (70a, 79a) abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, and providing positive support for said hexagonal panel.

2. A carton according to claim 1, wherein said hexagonal bottom panel is provided at its forward edge with a tab disposed at substantially a right angle thereto and engaging one of said side panels, thereby stabilizing and restraining said bottom panel.

3. A carton according to claim 1, wherein each of 4. A carton according to claim 1, wherein the top of said carton is provided with a closure comprising a plurality of closure flaps hingedly connected to the ends of said side panels and interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edges of said flap members passing through the center'of said closure when said flap members are in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure.

5. An integral blank for forming a carton in the form of a hexagonal prism having at least six side panels, and a bottom closure for said carton, said bottom closure comprising:

a. a hexagonal bottom flap being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton,

b. two supporting flap assemblies disposed one on each side of said hexagonal bottom flap, each of said assemblies comprising:

1. a supporting flap hingedly connected to the end of one of said side panels,

2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto, and

3. said glue flap being adapted to be adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion extending beyond the hinge line between said supporting member and said glue member when said carton is erected, and

c. one of said side panels being free of flap attachments at its lower edge, the arrangement being such that in the erected condition each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhang abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, providing positive support for said hexagonal flap.

6. An integral blank according to claim 5, wherein said hexagonal bottom panel is provided at its forward edge with a tab adapted to be disposed at substantially a right angle thereto and to engage one of said side panels, thereby stabilizing and restraining said bottom panel.

'7..A carton according to claim 5, wherein each of said supporting flaps (l) is trapezoidal in shape, wherein each of said glue flap members is triangular, and wherein the supporting flap member of said second supporting flap has an arcuate edge.

8. An integral blank according to claim 5, wherein the top of said carton is provided with a closure comprising a plurality of closure flaps hingedly connected to the ends of said side panels and, when glued, interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels, and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edge of said flap members adapted to pass through the center of said closure when in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure when in said closed condition. 

1. A carton in the form of a hexagonal prism having six side panels, and a bottom closure for said carton, said bottom closure comprising: a. a hexagonal bottom panel being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton, and b. two supporting flap assemblies disposed one immediately on each side of the side panel to which said hexagonal bottom panel is connected and below said polygonal bottom flap, each of saiD assemblies comprising:
 1. a first supporting flap hingedly connected to the end of one of said side panels,
 2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto,
 3. said second glue flap being adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion (70a, 79a) extending beyond the hinge line between said supporting member and said glue member and positioned over said second glue flap, thereby strengthening vertical support of said flap assembly, and
 4. one of said side panels being free of flap attachments at its lower edge, the arrangement being such that each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhanging portion (70a, 79a) abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, and providing positive support for said hexagonal panel.
 2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto,
 2. A carton according to claim 1, wherein said hexagonal bottom panel is provided at its forward edge with a tab disposed at substantially a right angle thereto and engaging one of said side panels, thereby stabilizing and restraining said bottom panel.
 2. a second supporting flap hingedly connected to the end of an adjacent one of said side panels comprising a supporting flap member and a glue flap member hingedly connected thereto, and
 3. said glue flap being adapted to be adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion extending beyond the hinge line between said supporting member and said glue member when said carton is erected, and c. one of said side panels being free of flap attachments at its lower edge, the aRrangement being such that in the erected condition each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhang abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, providing positive support for said hexagonal flap.
 3. A carton according to claim 1, wherein each of said supporting flaps (1) is trapezoidal in shape, wherein each of said glue flap members is triangular, and wherein the supporting flap member of said second supporting flap has an arcuate edge.
 3. said second glue flap being adhesively affixed to a medial portion of said first supporting flap and said first supporting flap having an overhanging portion (70a, 79a) extending beyond the hinge line between said supporting member and said glue member and positioned over said second glue flap, thereby strengthening vertical support of said flap assembly, and
 4. one of said side panels being free of flap attachments at its lower edge, the arrangement being such that each supporting flap assembly folds inwardly at the hinge line between said hinge member and said flap member permitting said bottom closure to be folded flat with the remainder of said carton for storage, and whereby when said carton is erected and said bottom closure is placed in planar position said overhanging portion (70a, 79a) abuts the upper surface of said supporting flap member, thereby restraining said flap assembly from bending outwardly of said carton, and providing positive support for said hexagonal panel.
 4. A carton according to claim 1, wherein the top of said carton is provided with a closure comprising a plurality of closure flaps hingedly connected to the ends of said side panels and interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edges of said flap members passing through the center of said closure when said flap members are in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure.
 5. An integral blank for forming a carton in the form of a hexagonal prism having at least six side panels, and a bottom closure for said carton, said bottom closure comprising: a. a hexagonal bottom flap being connected at one edge to the end of one of said side panels and having substantially the same dimensions and shape as the cross-section of said carton, b. two supporting flap assemblies disposed one on each side of said hexagonal bottom flap, each of said assemblies comprising:
 6. An integral blank according to claim 5, wherein said hexagonal bottom panel is provided at its forward edge with a tab adapted to be disposed at substantially a right angle thereto and to engage one of said side panels, thereby stabilizing and restraining said bottom panel.
 7. A carton according to claim 5, wherein each of said supporting flaps (1) is trapezoidal in shape, wherein each of said glue flap members is triangular, and wherein the supporting flap member of said second supporting flap has an arcuate edge.
 8. An integral blank according to claim 5, wherein the top of said carton is provided with a closure comprising a plurality of closure flaps hingedly connected to the ends of said side panels and, when glued, interconnected laterally to form a closed loop, each of said closure flaps comprising a flap member and a triangular web hingedly connected thereto, said flap members and said webs each having an edge perpendicular to the hinge line connecting said flap members and said side panels, and another edge oblique thereto, the oblique edges of said flap members and said webs being hingedly connected together, and the perpendicular edges of said flap members and triangular webs being connected to the perpendicular edges of webs and flap members, respectively, of adjacent closure flaps, the oblique edge of said flap members adapted to pass through the center of said closure when in closed condition, said flap members terminating in an arcuate tab extending beyond the center of said closure when in said closed condition. 